Extruded lightweight thermal insulating cement-based materials

ABSTRACT

An extrudable cement-based material is formed from a mixture that includes cement in the range of about 40 to 90% by wet weight percent, a lightweight expanded aggregate in the range of about 10 to 60% by wet weight percent, a secondary material in the range of about 0.1 to 50% by wet weight percent, a reinforcement fiber in the range of about 1 to 20% by wet weight percent, a rheology modifying agent in the range of about 0.5 to 10% by wet weight percent, a retarder in the range of about 0.1 to 8% by wet weight percent, and water in the range of 10 to 60% of a total wet material weight.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to, and is the National Stage ofInternational Application No. PCT/US2014/035277 filed on Apr. 24, 2014and claims priority to U.S. Provisional Patent Application Ser. No.61/815,308, filed on Apr. 24, 2013, U.S. Provisional Patent ApplicationSer. No. 61/815,328, filed on Apr. 24, 2013, U.S. Provisional PatentApplication Ser. No. 61/815,332, filed on Apr. 24, 2013, and U.S.Provisional Patent Application Ser. No. 61/820,850, filed on May 8,2013. The contents of both applications are hereby incorporated byreference herein in their entirety.

FIELD OF INVENTION

The present invention relates in general to cement-based materials, andmore particularly to extruded lightweight thermal insulatingcement-based materials.

BACKGROUND ART

Cement-based materials are generally produced using large amount ofwater to form a slurry that is too wet to extrude. Moreover,cement-based materials are generally not both lightweight and thermallyinsulating.

SUMMARY OF THE INVENTION

The present invention provides an extrudable lightweight thermalinsulating cement-based material that is formed from a mixture thatincludes cement in the range of about 40 to 90% by wet weight percent,water in the range of about 10 to 60%, a lightweight expanded aggregatein the range of about 5 to 40% by wet weight percent, a secondarymaterial (e.g., sand, rock, fly ash, slag, silica fume, calciumcarbonate, etc.) in the range of about 0.1 to 50% by wet weight percent,a reinforcement fiber in the range of about 1 to 20% by wet weightpercent, a rheology modifying agent in the range of about 0.5 to 10% bywet weight percent, and a retarder in the range of about 0.1 to 8% bydry weight percent.

In addition, the present invention provides a method for manufacturingan extrudable cement-based material by mixing a cement, a lightweightexpanded aggregate, a secondary material, a reinforcement fiber, arheology modifying agent and a retarder with water, extruding themixture through a die using an extruder, and allowing the extrudedmixture to set.

Moreover, the present invention provides a method of making theextrudable lightweight thermal insulating cement-based material(composite) by the following steps: (1) mixing about 40 to 90% Wt. wetcement with about 10 to 60% Wt. wet water; (2) blending the cement-watermixture with about 5 to 40% Wt. wet lightweight expanded aggregate,about 0.1 to 50% Wt. wet secondary material (e.g., sand, rock, fly ash,slag, silica fume, calcium carbonate, etc.), and about 1 to 20% Wt. wetreinforcement fiber; and (3) adding about 0.5 to 10% Wt. wet rheologymodifying agent and about 0.1 to 8% Wt. wet retarder to the mixture. Theresulting extrudable lightweight thermal insulating cement-basedmaterial can then be extruded and cured (e.g., allowed to sit, heating,steam, etc.).

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the features and advantages of thepresent invention, reference is now made to the detailed description ofthe invention along with the accompanying figures and in which:

Not applicable.

DESCRIPTION OF THE INVENTION

While the making and using of various embodiments of the presentinvention are discussed in detail below, it should be appreciated thatthe present invention provides many applicable inventive concepts thatcan be embodied in a wide variety of specific contexts. The specificembodiments discussed herein are merely illustrative of specific ways tomake and use the invention and do not delimit the scope of theinvention.

To facilitate the understanding of this invention, a number of terms aredefined below. Terms defined herein have meanings as commonly understoodby a person of ordinary skill in the areas relevant to the presentinvention. Terms such as “a”, “an,” and “the” are not intended to referto only a singular entity, but include the general class of which aspecific example may be used for illustration. The terminology herein isused to describe specific embodiments of the invention, but their usagedoes not delimit the invention, except as outlined in the claims.

Ordinary Portland cement or aluminate cement in its wet state with wateradded before setting, can be rheologically modified in to a clay-likematerial, which allows the use of the conventional clay productionmethod known as extrusion.

To make the cement-water mixture lightweight, it is blended with about5-40 wt. % of lightweight expanded aggregate of the total wet volume.The preferred lightweight expanded aggregate is either expanded clay,Perlite, expanded glass, expanded pumice, or a combination thereof. Theparticle size of the lightweight expanded aggregate is either about 0-1mm, 1-2 mm, 2-4 mm, 4-8 mm or a combination thereof. A process formaking the lightweight expanded glass or pumice aggregate will bedescribed after the discussion regarding the lightweight thermalinsulating cement-based material.

For extrusion, the cement-based lightweight thermal insulating compositewith approx. 10-60 wt. % water of the total wet material and a suitablerheology modifying admixture is made to feel and behave similar toplastic clay. The material feels plastic/deformable to the touch and canbe extruded similar to clay with the use of a clay extruder where thematerial is conveyed forward by an auger through a barrel and is formedcontinuously through a die into a final shape with form stability.

Depending on the water content and the amount of rheology modifyingadmixture, the extruded material can have more or less form stability.

To allow enough time of the cement-based material to be extruded beforesetting (hardening), the setting time can be retarded up to severalhours with the use of small additions of suitable set retarders such asSodate™ (USG Product) or sodium citrate. Sodate™ is a mixture of Plasterof Paris, sodium citrate and crystalline silica. Following extrusion,the material will within a few hours develop the final strength of thefinished product.

To develop the final 28 days strength, the product is either allowed tosit around for 28 days in a humid environment, or the strengthdevelopment can be accelerated within 24-48 hours by heating either byits own internal heat development or by steam curing such as isconventional in the state-of-the-art.

As will be described below, the present invention provides an extrudablecement-based material that is formed from a mixture that includes cementin the range of about 40 to 90% by dry weight percent, a secondarymaterial in the range of about 0.1 to 50% by dry weight percent, areinforcement fiber in the range of about 1 to 20% by dry weightpercent, a rheology modifying agent in the range of about 0.5 to 10% bydry weight percent, a retarder in the range of about 0.1 to 8% by dryweight percent, a water in the range of 10 to 50% of a total wetmaterial weight.

The cement can be used as a binder with water in a composite compositionin combination with a multitude of materials such as sand, gypsum,silica fume, fumed silica, fly ash, slag, rock, cellulose fiber, glassfiber, plastic fiber, polyvinyl alcohol (PVA) fiber, etc., or acombination thereof, which when rheologically modified can be extrudedas described above.

The rheology-modifying agents fall into the following categories: (1)polysaccharides and derivatives thereof, (2) proteins and derivativesthereof, and (3) synthetic organic materials. Polysacchariderheology-modifying agents can be further subdivided into (a)cellulose-based materials and derivatives thereof, (b) starch-basedmaterials and derivatives thereof, and (c) other polysaccharides.

Suitable cellulose-based rheology-modifying agents include, for example,methylhydroxyethylcellulose (MHEC), hydroxymethylethylcellulose (HMEC),carboxymethylcellulose (CMC), methylcellulose (MC), ethylcellulose (EC),hydroxyethylcellulose (HEC), hydroxyethylpropylcellulose (HEPC), orhydroxypropoylmethylcelluose (HPMC), etc.

Suitable starch-based materials include, for example, wheat starch,pre-gelled wheat starch, potato starch, pre-gelled potato starch,amylopectin, amylose, seagel, starch acetates, starch hydroxyethylethers, ionic starches, long-chain alkylstarches, dextrins, aminestarches, phosphate starches, and dialdehyde starches.

The currently preferred rheology-modifying agent ismethylhydroxypropylcellulose, examples of which are Methocel™ 240 andMethocel™ 240S, both of which are available from DOW Chemicals, USA.

The finished lightweight thermal insulating cement-based composite willhave densities in the range of about 0.2-1.0 g/cm³, compressivestrengths in the range of about 0.5 MPa-10 MPa and heat conductance inthe range of about 0.05-0.3 W/mK.

In one embodiment of the present invention, the compositional ranges ofcement-based material can be:

Component Wt. % Range of Wet Cement 40-90 Water 10-60 Lightweightexpanded aggregate  5-40 Secondary material (e.g., sand, 0.1-50  rock,fly ash, slag, silica fume, calcium carbonate, etc.) Reinforcement fiber 1-20 Rheology modifying agent 0.5-10  Retarder 0.1-8  

The cement can be about 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%,49%, 50%, 51%, 52%, 53%, 54%, 55%, 56%, 57%, 58%, 59%, 60%, 61%, 62%,63%, 64%, 65%, 66%, 67%, 68%, 69%, 70%, 71%, 72%, 73%, 74%, 75%, 76%,77%, 78%, 79%, 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89% or 90%by weight or other incremental percentage between.

The water can be about 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%,20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%,34%, 35%, 36%, 37%, 38%, 39%, 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%,48%, 49%, 50% 51%, 52%, 53%, 54%, 55%, 56%, 57%, 58%, 59% or 60% byweight or other incremental percentage between.

The lightweight expanded aggregate can be about 5%, 6%, 7%, 8%, 9%, 10%,11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%,25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%,39% or 40% by weight or other incremental percentage between.

The secondary material can be about 0.1%, 0.2%, 0.3%, 0.4%, 0.5%, 0.6%,0.7%, 0.8%, 0.9%, 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%,13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, 26%,27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, 40%,41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49% or 50% by weight or otherincremental percentage between.

The reinforcement fiber can be about 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%,10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19% or 20% by weight orother incremental percentage between.

The rheology modifying agent can be about 0.5%, 0.6%, 0.7%, 0.8%, 0.9%,1.0%, 1.1%, 1.2%, 1.3%, 1.4%, 1.5%, 1.6%, 1.7%, 1.8%, 1.9%, 2.0%, 2.1%,2.2%, 2.3%, 2.4%, 2.5%, 2.6%, 2.7%, 2.8%, 2.9%, 3.0%, 3.1%, 3.2%, 3.3%,3.4%, 3.5%, 3.6%, 3.7%, 3.8%, 3.9%, 4.0%, 4.1%, 4.2%, 4.3%, 4.4%, 4.5%,4.6%, 4.7%, 4.8%, 4.9%, 5.0%, 5.1%, 5.2%, 5.3%, 5.4%, 5.5%, 5.6%, 5.7%,5.8%, 5.9%, 6.0%, 6.1%, 6.2%, 6.3%, 6.4%, 6.5%, 6.6%, 6.7%, 6.8%, 6.9%,7.0%, 7.1%, 7.2%, 7.3%, 7.4%, 7.5%, 7.6%, 7.7%, 7.8%, 7.9%, 8.0%, 8.1%,8.2%, 8.3%, 8.4%, 8.5%, 8.6%, 8.7%, 8.8%, 8.9%, 9.0%, 9.1%, 9.2%, 9.3%,9.4%, 9.5%, 9.6%, 9.7%, 9.8%, 9.9%, 10.0% by weight or other incrementalpercentage between.

The retarder can be about 0.1%, 0.2%, 0.3%, 0.4%, 0.5%, 0.6%, 0.7%,0.8%, 0.9%, 1.0%, 1.1%, 1.2%, 1.3%, 1.4%, 1.5%, 1.6%, 1.7%, 1.8%, 1.9%,2.0%, 2.1%, 2.2%, 2.3%, 2.4%, 2.5%, 2.6%, 2.7%, 2.8%, 2.9%, 3.0%, 3.1%,3.2%, 3.3%, 3.4%, 3.5%, 3.6%, 3.7%, 3.8%, 3.9%, 4.0%, 4.1%, 4.2%, 4.3%,4.4%, 4.5%, 4.6%, 4.7%, 4.8%, 4.9%, 5.0%, 5.1%, 5.2%, 5.3%, 5.4%, 5.5%,5.6%, 5.7%, 5.8%, 5.9%, 6.0%, 6.1%, 6.2%, 6.3%, 6.4%, 6.5%, 6.6%, 6.7%,6.8%, 6.9%, 7.0%, 7.1%, 7.2%, 7.3%, 7.4%, 7.5%, 7.6%, 7.7%, 7.8%, 7.9%or 8.0% by weight or other incremental percentage between.

In addition, the present invention provides a method for manufacturingan extrudable lightweight thermal insulating cement-based material bymixing a cement, a lightweight expanded aggregate, a secondary material,a reinforcement fiber, a rheology modifying agent and a retarder withwater, extruding the mixture through a die using an extruder, andallowing the extruded mixture to set (e.g., up to 2 to 3 hours, etc).

Additional steps may include: (1) drying the extruded mixture; (2)curing the extruded mixture; (3) molding, cutting, trimming, sanding orrouting the extruded mixture into a specified shape; and/or (4) sprayingthe extruded mixture with a water repellent.

Following setting and drying of the finished product, the surface of thefinished product can be made water resistant with the use of silanes orsurface coatings.

Making the lightweight expanded aggregate from glass or pumice will nowbe described. The lightweight expanded glass or pumice aggregate can bemade as follows:

-   -   1) Grind glass or pumice in a ball mill to produce ground        material predominantly less than about 100 microns.    -   2) Mix the ground material with about 45-50% water to produce a        slurry.    -   3) Add about 6-7% sodium silicate (substitution ratio of 2.5) to        the slurry.    -   4) Add about 1% sodium nitrate (NaNO₃) to the slurry. This later        acts as a blowing agent.    -   5) Aggregates are produced in conventional granulator by feeding        about 1 part mixed slurry to 2.5 parts of ground pumice. By        varying the amount of water in the slurry and the ratio of        ground pumice to the slurry, the aggregate size can be tailored        to set a maximum final aggregate size.    -   6) Following, the formed aggregates are dried in a conventional        rotary drier.    -   7) Following, the dried aggregates together with about 30%        finely ground kaolin are fed into a rotary kiln where it is        heated between about 800-1400 degrees Celsius, during which        process the granules expand to its final size of about 0-8 mm        diameter and forms the light weight expanded aggregate.    -   8) Upon exiting the rotary kiln as last steps the aggregates are        cooled and then sieved to divide the aggregate into different        end use size ranges such as 0-2 mm, 2-4 mm and 4-8 mm.    -   9) Alternatively finer aggregates can be formed by following the        granulator, feeding the finer aggregates directly in to a flash        drier that heat the material above about 800 degrees Celsius and        creates expanded aggregates in the size of about 0-1 mm.

The finished lightweight expanded glass or pumice aggregate has adiameter of about 0-8 mm, a bulk density of about 0.10-0.50 g/cm³ and aneffective density of about 0.10-0.8 g/cm³. The aggregates further have acompressive strength of about 0.5-5 MPa and are very good heatinsulators with heat conductance of about 0.04-0.15 W/mK.

In one embodiment of the present invention, the compositional ranges ofthe expanded lightweight glass or pumice aggregate can be:

Component Wt. % Range Slurry: Ground glass or pumice 40-60 Water 40-60Sodium silicate  3-15 NaNO₃ 0.1-5   For granulator: Ground glass orpumice 50-85 Slurry 15-50

For the slurry, the ground glass or pumice can be about 40%, 41%, 42%,43%, 44%, 45%, 46%, 47%, 48%, 49%, 50%, 51%, 52%, 53%, 54%, 55%, 56%,57%, 58%, 59% or 60% by weight or other incremental percentage between.

For the slurry, the water can be about 40%, 41%, 42%, 43%, 44%, 45%,46%, 47%, 48%, 49%, 50%, 51%, 52%, 53%, 54%, 55%, 56%, 57%, 58%, 59% or60% by weight or other incremental percentage between.

For the slurry, the sodium silicate can be about 3%, 4%, 5%, 6%, 7%, 8%,9%, 10%, 11%, 12%, 13%, 14% or 15% by weight or other incrementalpercentage between.

For the slurry, the NaNO₃ can be about 0.1%, 0.2%, 0.3%, 0.4%, 0.5%,0.6%, 0.7%, 0.8%, 0.9%, 1%, 2%, 3%, 4% or 5% by weight or otherincremental percentage between.

For the granulator, the ground glass or pumice can be about 50%, 51%,52%, 53%, 54%, 55%, 56%, 57%, 58%, 59%, 60%, 61%, 62%, 63%, 64%, 65%,66%, 67%, 68%, 69%, 70%, 71%, 72%, 73%, 74%, 75%, 76%, 77%, 78%, 79%,80%, 81%, 82%, 83%, 84% or 85% by weight or other incremental percentagebetween.

For the granulator, the slurry can be about 15%, 16%, 17%, 18%, 19%,20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%,34%, 35%, 36%, 37%, 38%, 39%, 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%,48%, 49% or 50% by weight or other incremental percentage between.

In another embodiment of the present invention the compositional rangesof the expanded lightweight glass or pumice aggregate can be:

Component Wt. % Range Slurry: Ground glass or pumice 40-60 Water 45-50Sodium silicate 6-7 NaNO₃ 0.9-1.1 For granulator: 1 part slurry to 2.5parts ground glass or pumice

For the slurry, the ground glass or pumice can be about 40%, 41%, 42%,43%, 44%, 45%, 46%, 47%, 48%, 49%, 50%, 51%, 52%, 53%, 54%, 55%, 56%,57%, 58%, 59% or 60% by weight or other incremental percentage between.

For the slurry, the water can be about 45%, 46%, 47%, 48%, 49% or 50% byweight or other incremental percentage between.

For the slurry, the sodium silicate can be about 6.0%, 6.1%, 6.2%, 6.3%,6.4%, 6.5%, 6.6%, 6.7%, 6.8%, 6.9% or 7.0% by weight or otherincremental percentage between.

For the slurry, the NaNO₃ can be about 0.9%, 1.0% or 1.1% by weight orother incremental percentage between.

It may be understood that particular embodiments described herein areshown by way of illustration and not as limitations of the invention.The principal features of this invention can be employed in variousembodiments without departing from the scope of the invention. Thoseskilled in the art will recognize, or be able to ascertain using no morethan routine experimentation, numerous equivalents to the specificprocedures described herein. Such equivalents are considered to bewithin the scope of this invention and are covered by the claims.

All publications, patents and patent applications mentioned in thespecification are indicative of the level of skill of those skilled inthe art to which this invention pertains. All publications, patents andpatent applications are herein incorporated by reference to the sameextent as if each individual publication, patent or patent applicationwas specifically and individually indicated to be incorporated byreference.

The use of the word “a” or “an” when used in conjunction with the term“comprising” in the claims and/or the specification may mean “one,” butit is also consistent with the meaning of “one or more,” “at least one,”and “one or more than one.” The use of the term “or” in the claims isused to mean “and/or” unless explicitly indicated to refer toalternatives only or the alternatives are mutually exclusive, althoughthe disclosure supports a definition that refers to only alternativesand “and/or.” Throughout this application, the term “about” is used toindicate that a value includes the inherent variation of error for thedevice, the method being employed to determine the value, or thevariation that exists among the study subjects.

As used in this specification and claim(s), the words “comprising” (andany form of comprising, such as “comprise” and “comprises”), “having”(and any form of having, such as “have” and “has”), “including” (and anyform of including, such as “includes” and “include”) or “containing”(and any form of containing, such as “contains” and “contain”) areinclusive or open-ended and do not exclude additional, unrecitedelements or method steps.

The term “or combinations thereof” as used herein refers to allpermutations and combinations of the listed items preceding the term.For example, “A, B, C, or combinations thereof” is intended to includeat least one of: A, B, C, AB, AC, BC, or ABC, and if order is importantin a particular context, also BA, CA, CB, CBA, BCA, ACB, BAC, or CAB.Continuing with this example, expressly included are combinations thatcontain repeats of one or more item or term, such as BB, AAA, AB, BBC,AAABCCCC, CBBAAA, CABABB, and so forth. The skilled artisan willunderstand that typically there is no limit on the number of items orterms in any combination, unless otherwise apparent from the context.

All of the compositions and/or methods disclosed and claimed herein canbe made and executed without undue experimentation in light of thepresent disclosure. While the compositions and methods of this inventionhave been described in terms of preferred embodiments, it may beapparent to those of skill in the art that variations may be applied tothe compositions and/or methods and in the steps or in the sequence ofsteps of the method described herein without departing from the concept,spirit and scope of the invention. All such similar substitutes andmodifications apparent to those skilled in the art are deemed to bewithin the spirit, scope and concept of the invention as defined by theappended claims.

The invention claimed is:
 1. An extrudable lightweight thermalinsulating cement-based material formed from a mixture comprising: acement in the range of about 40 to 90% by wet weight percent; alightweight expanded aggregate comprising expanded glass, expandedpumice, or a combination thereof in the range of about 5 to 40% by wetweight percent; a secondary material in the range of about 0.1 to 50% bywet weight percent; a reinforcement fiber in the range of about 1 to 20%by wet weight percent; a rheology modifying agent in the range of about0.5 to 10% by wet weight percent; a retarder in the range of about 0.1to 8% by wet weight percent; a water in the range of 10 to 60% of atotal wet material weight; and the mixture is extrudable.
 2. Theextrudable lightweight thermal insulating cement-based material asrecited in claim 1, the expanded glass or the expanded pumice formedfrom a mixture comprising: a ground glass or pumice in the range ofabout 40 to 60% by weight percent for a slurry; a water in the range ofabout 40 to 60% by weight percent for the slurry; a sodium silicate inthe range of about 3 to 15% by weight percent for the slurry; a NaNO₃ inthe range of about 0.1 to 5% for the slurry; the ground glass or pumicein the range of about 50 to 80% by weight percent for a granulator; theslurry in the range of about 15 to 50% by weight percent for thegranulator; and wherein the mixture is processed using the slurry andthe granulator such that the expanded lightweight aggregate has amaximum final aggregate size.
 3. The extrudable lightweight thermalinsulating cement-based material as recited in claim 2, the granulatorhaving a ratio of about 1 part slurry to about 2.5 parts ground glass orpumice.
 4. The extrudable lightweight thermal insulating cement-basedmaterial as recited in claim 1, the expanded glass or the expandedpumice formed from a mixture consisting essentially of: a ground glassor pumice in the range of about 40 to 60% by weight percent for aslurry; a water in the range of about 40 to 60% by weight percent forthe slurry; a sodium silicate in the range of about 3 to 15% by weightpercent for the slurry; a NaNO₃ in the range of about 0.1 to 5% for theslurry; the ground glass or pumice in the range of about 50 to 80% byweight percent for a granulator; the slurry in the range of about 15 to50% by weight percent for the granulator; and wherein the mixture isprocessed using the slurry and the granulator such that the expandedlightweight aggregate has a maximum final aggregate size.
 5. Theextrudable lightweight thermal insulating cement-based material asrecited in claim 1, the expanded glass or the expanded pumice formedfrom a mixture comprising: a ground glass or pumice in the range ofabout 40 to 60% by weight percent for a slurry; a water in the range ofabout 45 to 50% by weight percent for the slurry; a sodium silicate inthe range of about 6 to 7% by weight percent for the slurry; a NaNO₃ inthe range of about 0.9 to 1.1% for the slurry; and wherein a granulatorforms the expanded glass or the expanded pumice using a ratio of 1 partslurry to about 2.5 parts ground glass or pumice.
 6. The extrudablelightweight thermal insulating cement-based material as recited in claim1, the expanded glass or the expanded pumice having a diameter of about0-8 mm, a bulk density in the range of about 0.10 to 0.5 g/cm³, aeffective density in the range of about 0.10 to 0.8 g/cm³, a compressivestrength in the range of about 0.5 MPa to 5 MPa, and a heat conductancein the range of about 0.04 to 0.15 W/mK.
 7. The extrudable lightweightthermal insulating cement-based material as recited in claim 1, thelightweight expanded aggregate having a particle size comprising about0-1 mm, 1-2 mm, 2-4 mm, 4-8 mm or a combination thereof.
 8. Theextrudable lightweight thermal insulating cement-based material asrecited in claim 1, the secondary material comprising sand, gypsum,silica fume, fumed silica, fly ash, slag, rock, or a combinationthereof.
 9. The extrudable lightweight thermal insulating cement-basedmaterial as recited in claim 1, the reinforcement fiber comprisingcellulose fiber, glass fiber, plastic fiber, polypropylene fiber,polyvinyl alcohol (PVA) fiber, homopolymer acrylic fiber, or acombination thereof.
 10. The extrudable lightweight thermal insulatingcement-based material as recited in claim 1, the rheology modifyingagent comprising a polysaccharide, a polysaccharide derivative, aprotein, a protein derivative, a synthetic organic material, a syntheticorganic material derivative, or a combination thereof.
 11. Theextrudable lightweight thermal insulating cement-based material asrecited in claim 10, the polysaccharide comprising a cellulose-basedmaterial, a cellulose-based material derivative, a starch-basedmaterial, a starch-based material derivative, or a combination thereof.12. The extrudable lightweight thermal insulating cement-based materialas recited in claim 11, the cellulose-based material is selected fromthe group consisting of methylhydroxyethylcellulose (MHEC),hydroxymethylethylcellulose (HMEC), carboxymethylcellulose (CMC),methylcellulose (MC), ethylcellulose (EC), hydroxyethylcellulose (HEC),hydroxyethylpropylcellulose (HEPC) and hydroxypropoylmethylcelluose(HPMC).
 13. The extrudable lightweight thermal insulating cement-basedmaterial as recited in claim 11, the starch-based material is selectedfrom the group consisting of wheat starch, pre-gelled wheat starch,potato starch, pre-gelled potato starch, amylopectin, amylose, seagel,starch acetates, starch hydroxyethyl ethers, ionic starches, long-chainalkylstarches, dextrins, amine starches, phosphate starches, ordialdehyde starches.
 14. The extrudable lightweight thermal insulatingcement-based material as recited in claim 1, the retarder comprisingsodium citrate, or a mixture of Plaster of Paris, sodium citrate andcrystalline silica.
 15. The extrudable lightweight thermal insulatingcement-based material as recited in claim 1, the extrudable lightweightthermal insulating cement-based material having a density in the rangeof about 0.2 to 1.0 g/cm³, a compressive strength in the range of about0.5 MPa to 10 MPa, and a heat conductance in the range of about 0.05 to0.3 W/mK.
 16. An extrudable lightweight thermal insulating cement-basedmaterial formed from a mixture consisting essentially of: a cement inthe range of about 40 to 90% by wet weight percent; a lightweightexpanded aggregate comprising expanded glass, expanded pumice, or acombination thereof in the range of about 5 to 40% by wet weightpercent; a secondary material in the range of about 0.1 to 50% by wetweight percent; a reinforcement fiber in the range of about 1 to 20% bywet weight percent; a rheology modifying agent in the range of about 0.5to 10% by wet weight percent; a retarder in the range of about 0.1 to 8%by wet weight percent; a water in the range of 10 to 60% of a total wetmaterial weight; and the mixture is extrudable.
 17. A method formanufacturing an extrudable lightweight thermal insulating cement-basedmaterial comprising the steps of: mixing a cement in the range of about40 to 90% by wet weight percent, a lightweight expanded aggregatecomprising expanded glass, expanded pumice, or a combination thereof inthe range of about 5 to 40% by wet weight percent, a secondary materialin the range of about 0.1 to 50% by wet weight percent, a reinforcementfiber in the range of about 1 to 20% by wet weight percent, a rheologymodifying agent in the range of about 0.5 to 10% by wet weight percentand a retarder in the range of about 0.1 to 8% by wet weight percentwith water in the range of 10 to 60% of a total wet material weight;extruding the mixture through a die using an extruder; and allowing theextruded mixture to set.
 18. The method as recited in claim 17, theexpanded glass or the expanded pumice formed from a mixture comprising:a ground glass or pumice in the range of about 40 to 60% by weightpercent for a slurry; a water in the range of about 40 to 60% by weightpercent for the slurry; a sodium silicate in the range of about 3 to 15%by weight percent for the slurry; a NaNO₃ in the range of about 0.1 to5% for the slurry; the ground glass or pumice in the range of about 50to 80% by weight percent for a granulator; the slurry in the range ofabout 15 to 50% by weight percent for the granulator; and wherein themixture is processed using the slurry and the granulator such that theexpanded lightweight aggregate has a maximum final aggregate size. 19.The method as recited in claim 18, the granulator having a ratio ofabout 1 part slurry to about 2.5 parts ground glass or pumice.
 20. Themethod as recited in claim 17, the expanded glass or the expanded pumiceformed from a mixture consisting essentially of: a ground glass orpumice in the range of about 40 to 60% by weight percent for a slurry; awater in the range of about 40 to 60% by weight percent for the slurry;a sodium silicate in the range of about 3 to 15% by weight percent forthe slurry; a NaNO₃ in the range of about 0.1 to 5% for the slurry; theground glass or pumice in the range of about 50 to 80% by weight percentfor a granulator; the slurry in the range of about 15 to 50% by weightpercent for the granulator; and wherein the mixture is processed usingthe slurry and the granulator such that the expanded lightweightaggregate has a maximum final aggregate size.
 21. The method as recitedin claim 17, the expanded glass or the expanded pumice formed from amixture comprising: a ground glass or pumice in the range of about 40 to60% by weight percent for a slurry; a water in the range of about 45 to50% by weight percent for the slurry; a sodium silicate in the range ofabout 6 to 7% by weight percent for the slurry; a NaNO₃ in the range ofabout 0.9 to 1.1% for the slurry; and wherein a granulator forms theexpanded glass or the expanded pumice using having a ratio of 1 partslurry to about 2.5 parts ground glass or pumice.
 22. The method asrecited in claim 17, the expanded glass or the expanded pumice having adiameter of about 0-8 mm, a bulk density in the range of about 0.10 to0.5 g/cm³, a effective density in the range of about 0.10 to 0.8 g/cm³,a compressive strength in the range of about 0.5 MPa to 5 MPa, and aheat conductance in the range of about 0.04 to 0.15 W/mK.
 23. The methodas recited in claim 17, further comprising, prior to mixing the cement,the step of making the lightweight expanded aggregate comprising thesteps of: mixing a ground glass or pumice in the range of about 40 to60% by weight percent with water in the range of about 40 to 60% byweight percent to produce a slurry; adding a sodium silicate in therange of about 3 to 15% by weight percent to the slurry; adding a NaNO₃in the range of about 0.1 to 5% to the slurry; forming aggregates in agranulator by feeding the ground glass or pumice in the range of about50 to 80% by weight percent with the slurry in the range of about 15 to50% by weight percent; drying the formed aggregates; heating the driedaggregates together with about 30% finely ground kaolin to a temperatureof about 800 to 1400 degrees Celsius; and cooling the heated aggregates.24. The method as recited in claim 17, the lightweight expandedaggregate having a particle size comprising about 0-1 mm, 1-2 mm, 2-4mm, 4-8 mm or a combination thereof.
 25. The method as recited in claim17, the secondary material comprising sand, gypsum, silica fume, fumedsilica, fly ash, slag, rock, or a combination thereof.
 26. The method asrecited in claim 17, the reinforcement fiber comprising cellulose fiber,glass fiber, plastic fiber, polypropylene fiber, polyvinyl alcohol (PVA)fiber, homopolymer acrylic fiber, or a combination thereof.
 27. Themethod as recited in claim 17, the rheology modifying agent comprising apolysaccharide, a polysaccharide derivative, a protein, a proteinderivative, a synthetic organic material, a synthetic organic materialderivative, or a combination thereof.
 28. The method as recited in claim27, the polysaccharide comprising a cellulose-based material, acellulose-based material derivative, a starch-based material, astarch-based material derivative, or a combination thereof.
 29. Themethod as recited in claim 28, the cellulose-based material is selectedfrom the group consisting of methylhydroxyethylcellulose (MHEC),hydroxymethylethylcellulose (HMEC), carboxymethylcellulose (CMC),methylcellulose (MC), ethylcellulose (EC), hydroxyethylcellulose (HEC),hydroxyethylpropylcellulose (HEPC) and hydroxypropoylmethylcelluose(HPMC).
 30. The method as recited in claim 28, the starch-based materialis selected from the group consisting of wheat starch, pre-gelled wheatstarch, potato starch, pre-gelled potato starch, amylopectin, amylose,seagel, starch acetates, starch hydroxyethyl ethers, ionic starches,long-chain alkylstarches, dextrins, amine starches, phosphate starches,or dialdehyde starches.
 31. The method as recited in claim 17, theretarder comprising sodium citrate, or a mixture of Plaster of Paris,sodium citrate and crystalline silica.
 32. The method as recited inclaim 17, the extruded mixture having a density in the range of about0.2 to 1.0 g/cm³, a compressive strength in the range of about 0.5 MPato 10 MPa, and a heat conductance in the range of about 0.05 to 0.3 W/mKafter being set, cured or dried.
 33. The method as recited in claim 17,wherein the extruded mixture is allowed to set for 2 to 3 hours.
 34. Themethod as recited in claim 17, further comprising the step of curing theextruded mixture.
 35. The method as recited in claim 17, furthercomprising the step of drying the extruded mixture.
 36. The method asrecited in claim 17, further comprising the step of molding, cutting,trimming, sanding or routing the extruded mixture into a specifiedshape.
 37. The method as recited in claim 17, further comprising thestep of spraying the extruded mixture with a water repellent.